ApenGroup Aermax line User, Installation, And Maintenance Manual Download Page 1

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Page 1

APEN GROUP reserves the right to change products and documents as required.

code HG0109.12GB ed.C-1106 rev.12

WARM AIR HEATER SERIES RAPID

RAPID

Warm Air Heater

ON-OFF

It is forbidden to totally or partially copy or reproduce this document for disclosure to third parties without written consent by

Apen Group

s.p.a.

User,

Installation,

and

Maintenance Manual

NEW SERIES

Summary of Contents for Aermax line

Page 1: ... HG0109 12GB ed C 1106 rev 12 WARM AIR HEATER SERIES RAPID RAPID Warm Air Heater ON OFF It is forbidden to totally or partially copy or reproduce this document for disclosure to third parties without written consent by Apen Group s p a User Installation and Maintenance Manual NEW SERIES ...

Page 2: ...Page 2 code HG0109 12GB ed C 1106 rev 12 APEN GROUP reserves the right to change products and documents as required WARM AIR HEATER SERIES RAPID ...

Page 3: ...AC has been designed and manufactured in compliance with the prescriptions of the following EC Directives Machinery Directive 2006 42 CE Gas Appliance Directive 90 396 CEE Electromagnetic Compatibility Directive 2004 108 CE Low Voltage Directive 2006 95 CE If the unit is to be installed into an equipment combined the manufacturer disclaims any responsibility if this equipment is not previously dec...

Page 4: ...er 10 4 2 Heater Operation 10 4 3 Accessories 11 SECTION 5 INSTRUCTIONS FOR THE INSTALLER 12 5 1 General Installation Rules 12 5 2 Installing the Heater 12 5 3 Chimney Piping 15 5 4 Terminal Layout 17 5 5 Electrical Wiring 20 5 6 Gas Supply System 23 SECTION 6 INSTRUCTIONS FOR SERVICE STAFF 24 6 1 Country Table Gas Category 24 6 2 Gas Setting Data Table 25 6 3 First Startup 26 6 4 Combustion Analy...

Page 5: ...ed Gas Directive 2009 142 CE Low Voltage Directive 2006 95 EEC Machinery Directive 2006 42 CE Electromagnetic Compatibility Directive 2004 108 CE 2 SAFETY WARNINGS This section describes the safety rules for operators 2 1 Fuel Before starting the heater check that Gas supply specifications match those written on the rating plate Combustion air inlet pipes if installed and flue discharge pipes are ...

Page 6: ...h gas cocks and disconnect the unit from power supply If the unit is to be definitively decommissioned in addition to above suggestions any potential source of hazard shall have to be made inoffensive It is mandatory that the inlet of the Venturi tube on the burner fan assembly is kept free from any debris or obstructions see figure in this page In case it is not a backfire from the pre mix burner...

Page 7: ...gas equipment set by EN1020 regulations The combustion chamber is entirely built in AISI 430 stainless steel while tube bundles are made ofAISI 441 in order to assure high resistance to corrosion of wet flue The leading edge design and the wide surface of the furnace and tube bundle guarantee optimum efficiency and durability The burner is entirely built with stainless steel and it takes advantage...

Page 8: ...1 x 400 1 x 420 2 x 400 2 x 420 Fan speed g 1 1 050 1 270 1 270 1 350 1 270 1 350 NOISE LEVEL UOM max Noise level Lw dB A 66 4 70 9 74 1 73 9 77 1 Noise level in free field 6m Lp dB A 39 9 44 4 47 5 47 4 50 5 Minimum operating temperature C 15 0 60 0 Heater net weight unpacked Kg 59 65 69 75 92 97 Heater gross weight packed Kg 70 80 84 90 112 117 RAC024 RAC032 RAC035 RAC043 RAC054 TECHNICAL DATA U...

Page 9: ... be found outdoor away from walls or obstacles or in a semi anechoic chamber The accuracy of the measu rement depends on the en gineering method used 2nd degree Thereproducibilityof the results obtained in diffe rent test environments can beexpressedwithastandard deviation below 1 5 dB APEN GROUP has chosen to use one speed fans in order to increase the air flow rateandtheoutputefficiency of the e...

Page 10: ...02 HEATER SIZE LOUVER BRACKETS GAS SUPPLY MODEL L B H V HB LB IM IS ID DM GAS GO GV RA015 720 640 650 140 530 415 450 116 174 475 3 4 186 263 RA024 900 595 206 264 RA032 RA035 RA043 1240 935 780 228 252 RA054 740 620 183 352 HEATER STANDARD HORIZONTAL OUTLETS MODEL A F AV TV S RA015 80 80 367 204 105 RA024 RA032 RA035 RA043 RA054 457 HEATER OPT VERT OUTLETS TOP HOLES MODEL A F AO TO S D1 D2 D3 D4 ...

Page 11: ...ers for heaters with eased frame are considered accessories and are not supplied with the equipment HEATER DIMENSIONS DELIVERY SHUTTERS INTAKE FILTERS MODEL T DM C N M HM LM BS HS LS BF HF LF 024 1225 260 520 102 155 500 600 80 410 510 105 400 500 032 035 043 1315 200 580 90 125 550 950 460 710 450 700 054 145 650 510 500 HEATER BRACKETS MODEL IS IM ID 024 52 595 252 032 035 043 910 277 054 960 22...

Page 12: ...ese are the prerequisites to launch burner start up cycle The flame control device starts up the burner that launches the furnace pre washing phase The flame is lit about 30 seconds afterwards A detection electrode checks the burner has actually fired In case it has not the start up sequence is repeated 4 times before locking the unit 30 seconds after the burner is fired the fan automatically star...

Page 13: ...you want to remotely control the Sum mer Winter mode please leave the switch on the heater turned on Winter pos I If you power off the unit before cooling cycle is completed and then power it on again fans star immediately HG0100 C2 012 4 3 Accessories To ease the use of the heater APEN can supply two accessories that allow to remotely control heater s commands Available commands are described bel...

Page 14: ...amontherightshowsinstallationheightandclearance of the heater from walls and floor Minimum clearance in mm indicates the space required to assure proper maintenance Height 2 500 mm is the minimum value required by the law for wall mounted heaters In front of the heater a clearance of at least 3 meters shall be provided Behind the unit the space mustbeequalorgreaterthan DM valueshownin Dimensions p...

Page 15: ...ouvers for RA054 Install the louvers using pre drilled holes in heater upper and lower panel WALL MOUNTED HEATER Toinstalltheheaterusingeye bolts akitisavailable G14444 08 Simply replace upper screws with eye bolts VERTICAL HEATER Rapid heaters can be installed with downwards air blow vertical air flow This type of heater is not standard as it includes G14437 08 kit and additional thermostats for ...

Page 16: ...ed frame tighten M8 screws supplied in the kit to the nuts on eased frame To fasten filters to the shutter both nuts and M8 screws are needed WIRING THE EASED FRAME Inside burner compartment a relay is already wired to wiring card The wire from eased frame shall be wired to this relay as described in the figure No problem if brown and grey wires are reversed Contact NO 14 5 Contact 44 8 Gray wire ...

Page 17: ... building flue system because flue temperatures are higher than those allowed by these materials Condensate Withfluelayoutslongerthan8metersifrunningindoor orlonger than 5 meters if running outdoor condensate may appear in flue pipes If so a condensate manifold code G15825 08 HV should be installed between the heater and the flue system to collect condensation water This kit can be used both on ho...

Page 18: ...zontal C13 concentric terminal 5 5 14 23 28 42 62 TC13 08 HC3 Ø 100 100 horizontal C13 concentric terminal 2 5 5 10 13 21 8 34 5 TC13 10 HC3 Ø 100 100 horizontal C13 concentric terminal small 2 4 6 7 12 15 4 25 4 39 9 TC13 10 HC3R Ø 130 130 horizontal C13 concentric terminal 1 2 2 8 3 5 4 9 7 TC13 13 HC3 Ø 130 130 horizontal C13 concentric terminal small 1 2 2 6 4 4 9 7 1 10 2 TC13 13 HC3R Ø 80 80...

Page 19: ...S0 Pipes and elbows Ø80 Model meters RA015 30 RA024 30 RA032 29 RA035 26 RA043 22 RA054 17 Max L1 of layout terminal excluded Terminal Ø80 TB23 08 HS0 Pipes and elbows Ø80 Model meters RA015 29 RA024 29 RA032 26 RA035 24 RA043 20 RA054 15 HG0109 12_ET_009 A 5 4 Terminal Layout B23 TYPE Open combustion circuit combustion air intake from indoor flue are exhausted outdoor In this case UNI CIG 7129 an...

Page 20: ...80 80 TC13 08 HC3 Term Ø100 100 TC13 10 HC3 Pipes and elbows Ø80 Pipes and elbows Ø100 Model Meters RA015 10 10 RA024 10 10 RA032 10 10 RA035 9 9 RA043 7 7 9 9 RA054 4 5 4 5 10 10 REMARK Max possible length was equally divided between intake and discharge Different ratios are allowed provided the maximum value shown in the table is not exceeded Max L1 L2 of layout terminal excluded Term Ø80 80TC13...

Page 21: ...Intake terminal Ø100 with grid Outer and inner wall plates Fastening accessories 15 14 13 11 HG0103 C2 015 C53 TYPE Sealed combustion circuit from the room Pipe systems are connected one to the roof and the other to the wall HG0109 12_ET_012 Max L1 L2 of layout terminal excluded Discharge Ø80 TB23 08 VS0 Intake Ø80 TC00 08 HS0 Discharge Ø100 TB23 08 VS0 Intake Ø100 TC00 08 HS0 Pipes and elbows Ø80...

Page 22: ...ne E cover and its seal on the side hole of the exchanger 2 Install B flue junction on upper hole of the exchanger 3 Insert intake junction D on burner compartment 4 Cut to length C pipe and install it on D air junction reaching same height as flue outlet 5 Install pre cut covers A and their seals on the hole for air intake 6 Install E cover without seal on back hole of the flue Disassembling Asse...

Page 23: ...an be plugged into mains using a plug socket only if the latter prevents any mistake between phase and neutral wires The system wire gauge in general and cable section in parti cular must suit the unit rated input see technical data table Keep cables far from heat sources REMARK A multipole cut out switch must be installed before the heater with suitable electric protection The section of supply c...

Page 24: ...ontrol G00094remotecontrolincludesaroomthermostat asummer winter switch a reset and lock signaling LED and is delivered with a multipole numbered cable already wired To wire the control to the heater do the following Wireremotecontrolnumberedwires 2to6 to31 36terminals of relevant board see diagram in this page Make sure the summer winter switch installed on the heater is turned on I WINTER HG109 ...

Page 25: ...he law allows a maximum pressure of 40 mbar inside the buildingorthermalplant Higherpressurevaluesshallbereduced before the room where the heater is installed LEGEND 1 Main burner gas solenoid valve 2 Pressure stabilizer 3 Safety solenoid valve 4 Gas filter small section 5 Vibration damping joint 6 Gas filter large section 7 Gas cock Supplied with RAPID heater 1 2 3 4 5 6 7 To be installed by the ...

Page 26: ...has been set and tested for Liquid Propane G31 RA043NL xxx2 2 indicates the unit has been set and tested for natural gas L G25 RA043HU xxx3 3 indicates the unit has been set and tested for natural gas G25 1 RA043PL xxx4 4 indicates the unit has been set and tested for G2 350 gas Another label on the unit placed near fuel supply clearly states which gas type and supply pressure the unit has been se...

Page 27: ... max 57 5 Ø GAS DIAPHRAGM mm 2 5 3 5 5 1 5 1 6 0 6 5 Ø AIR DIAPHRAGM mm 13 0 18 0 23 0 24 0 28 0 29 0 CARBON DIOXIDE CO2 10 8 0 2 GAS CONSUMPTION 15 C 1013mbar Kg h 1 06 1 71 2 24 2 49 3 06 3 73 G31 GAS TYPE TYPE OF APPLIANCE RA015 RA024 RA032 RA035 RA043 RA054 CATEGORY Based on target country see table 6 1 SUPPLY PRESSURE mbar 30 min 25 max 35 37 min 25 max 45 50 min 42 5 max 57 5 Ø GAS DIAPHRAGM...

Page 28: ...t a flue gas content analyzer to the chimney and check CO2 value comparing it to the one listed in the Gas Setting Data point 6 2 table referred to the kind of fuel used If this value is not included in the required range regulate CO2 value by adjusting the screw on the Venturi turn it clockwise to decrease gas flow thereby decreasing also CO2 value and counter clockwise to increase it 6 5 Convert...

Page 29: ...into them or using suitable tools Remove dust from air intake terminal 3 Checking and cleaning the Venturi If necessary use a brush to remove dust on the Venturi inlet taking care not to let it drop inside 6 6 Conversion to G25 G25 1 G2 350 Gas The conversion to another type of gas shall be carried out exclusively by an APEN GROUP certified Service Centre Conversion from G20 into G25 is only allow...

Page 30: ...locks Coolthebulb thenreset thisprocedure must be carried out on each thermostat assembled on the unit 8 Ionization Current Carry out this operation using a device capable of testing direct current microamperes Do the following Disconnect the unit from power supply Disconnect flame control device cable and connect it to the negative pole of the tester Use a wire to connect the positive pole of the...

Page 31: ...than 5 secs Red LED will start flashing in sequen ces separated by a pause of 2 secs The number of flashes in each sequence indicates the fault number Check in the following table fault numbers and relevant meaning Fault Codes Meaning Number of flashes Possible reason 1 Flash No detection of flame signal and timeout of safety card exceeded Detection electrode wrongly positioned No fuel Fuel valves...

Page 32: ...cluded SP1 Socket plug to power the unit ACF Flame control device EVG Gas solenoid valve STB1 2 Safety thermostat manual reset TR AC Start up transformer EA Start up electrode ER Detection electrode TR 230 24V 63 VA transformer VAG Burner fan LV Green LED 230V unit powered LR Red LED 230V lock D1 Summer winter switch SB Reset Button SB Air fans F1 4 AT fuse on board delayed R1 Relays of air fans W...

Page 33: ...Diagram code JG0402 00 For connections see section on Installation Component Legend IG Voltage disconnect switch not included SP1 Socket plug to power the unit ACF flame control device EVG Gas solenoid valve STB1 2 Safety thermostat manual reset TR AC Start up transformer EA Start up electrode ER Detection electrode TR 230 24V 63 VA transformer VAG Burner fan LV Green LED 230V unit powered LR Red ...

Page 34: ...Page 34code HG0109 12GB ed C 1106 rev 12 APEN GROUP reserves the right to change products and documents as required WARM AIR HEATER SERIES RAPID 9 APPROVAL CERTIFICATE ...

Page 35: ...Page 35 APEN GROUP reserves the right to change products and documents as required code HG0109 12GB ed C 1106 rev 12 WARM AIR HEATER SERIES RAPID ...

Page 36: ...NER GASKET Code Model G14086 015 054 BURNER HEAD Code Model G14534 P 015 024 G14375 01 P 032 035 G16340 01 P 043 G14370 01 P 054 Ø 8 GASKET Code Model G02285 015 054 FLANGE FUSION Code Model G16160 15 054 FAN GASKET Code Model G14086 015 054 AIR GAS VENTURI Code Model G14898 015 G14899 024 G14068 032 035 G14154 043 054 START UP GROUP WITH ELECTRODES Code Model G15020 02 015 054 GASKET Code Model G...

Page 37: ...54 FLAME CONTROL DEVICE Code Model G04600 015 054 FUSE 6 3A ST Code Model X00519 015 035 CLOSING HANDLE Code Model G14531 015 054 GASKET Ø 80 Code Model G04378 015 054 REMOVABLE PLUG Code Model G12063 015 054 HG0109 09_C2_007 AIR TERMINAL Code Model G01239 015 054 HINGE Code Model X00536 015 054 FIXED PLUG Code Model G12064 01 015 054 MODEL Fan RA015 C09250 Hidria 1 RA024 32 G03270 Hidria 1 RA035 ...

Page 38: ... as required WARM AIR HEATER SERIES RAPID HORIZONTAL LOUVER Code Model G15213 S 015 G15313 S 024 032 035 G15333 S 043 G15353 S 054 HG0109 12_C2_015 pdf LEDs Code Model G14992 01 015 054 Red G14991 01 015 054 Green SUMMER 0 WINTER SWITCH Code MODEL G12209 01 015 054 RESET BUTTON Code MODEL G13268 015 054 ...

Page 39: ...______________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ ___________________________________________...

Page 40: ...and documents as required WARM AIR HEATER SERIES RAPID APEN GROUP S p A Capitale sociale E 928 800 interamente versato 20060 Pessano con Bornago Milan Via Isonzo 1 Tel 39 2 9596931 Fax 39 2 95742758 Website http www apengroup com E mail apen apengroup com Tax Registration Number 08767740155 ...

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